Manufacture of metal products



Aug 28, 1945- H. A. BRAssERT A2,383,766

MANUFACTRE 0F METAL PRODUCTS Filed May 14, 1945 2 Sheets-Sheet l I 2 Sheets-Shea?I 2 Aug. 28,'1945. H. A. BRAssERT MANUFACTURE OF METAL PRODUCTS Filed May 14, 1945 Patented Aug. 2 8, 1945 MANUFACTURE F METAL PRODUCTS Herman A. Brassert, Washington, Conn., assignor to H. A. Brassert & Company, NewYork, N. Y., a corporation of Illinois Application May 14, 1943, Serial No. 486,989

4 Claims.

This invention relates to the manufacture of metal products and has particular reference to an apparatus for direct manufacture of finished or semi-finished iron and steel products from iron oxides.

Iron and steel products are usually manufactured either by rolling, forging, or extruding a billet of iron or steel initially formed from molten metal, or by assembling bars of Wrought iron or soft steel to form a billet of the proper size and heating it to the proper temperature for rolling, forging, or extrusion to the desired finished or semi-finished shape. These processes are intermittent and involve substantial loss of time and heat as the result of transfer from one station to another. Such products have also been produced by directly reducing finely-divided iron oxides and compacting the reduced particles into a billet which is then heated to the proper temperature.

and rolled, forged, or extruded to the desired shape. This last-named process is disclosed in Patent No. 2,252,697, issued August 19, 1941, to applicant, and is admirably suited for producing relatively small-dimensioned products from cor` respondingly small compacted billets or briquettes, but when large products or a plurality of small products are to be extruded from a single large billet, non-uniform products frequently result, be.. cause of the practical impossibility of compacting the reduced grains to the same degree throughout any cross-section of a large compacted billet. This non-uniform density in a large billet is probably due to the irregular shapes of the particles and consequent friction between them during compacting, which precludes uniform pressure throughout While they are being compacted, so that whereas the billet has a dense surface skin, the density gradually decreases toward the center or core of the billet. Theoretically, this condition could be remedied either by increasing thek Vapparatus is provided for continuously producing Y uniform iron and steel products in finished or semi-finished form from a large billet of uniform density throughout, produced directly from finely-divided iron oxides as a continuous process without material loss of heat or time.

The invention comprises apparatus for directly reducing finely-divided iron oxides at temperatures below those at which the particles agglomerate or frit together, compacting means for compressing the reduced material while still in a reducing atmosphere and hot from the reducing operation into relatively large plate-like briquettes, means for superimposing such plate-like briquettes to form a stack of a size desired for the billet, a furnace for heating the assembled platelike briquettes to the extruding or rolling-temperature, not only to prepare them for rolling or extrusion, but also t0 consolidate or weld the grains together and to partially fuse the stacked briquettes to each other, and finally apparatus for compressing, forging, rolling or extruding the resulting hot billet into the desired finished or semifinished product, said means and apparatus being arranged to conduct a continuous process to oonserve heat and in a reducing atmosphere to preclude reoxidation. Preferably the plate-like briquettes are rolled to provide a corrugated transverse cross-section so that they will automatically t together without disarrangement during subsequent handling, heating, and rolling, forging or extruding process, and, if desired, transverse corrugations may also be provided to preclude `endwise shifting of the plate-like briquettes. Also compressing or compacting in a press may precede forging or rolling or extrusion and in' order to consolidate the material into a more solid, basic workable blank or billet.

It will be seen that the apparatus of this invention provides a very effective and simple arrangement for directly obtaining a large billet of substantially homogeneous density, since the material constituting it is in effect compacted as.

separate units of the whole, with the result that when the product is finished its grain structure is uniform throughout, notwithstanding that it was formed initially of fine, discrete particles. In this way the economy of forming finished or semifinished products from a large billet is realized. By addition of modifying agents, such as alloying metals in finely-divided form, carbon and the like, virtually any composition of the finished product to provide desired physical properties may be obtained, these materials being admixed withthe reduced material prior to briquetting into the plate-like briquettes described.

Fora more complete understanding of the invention, reference may be had to the accompanying drawings, in which:

Figure 1 is a partially schematic representation of apparatus oi' this invention;

Fig 2 is a horizontal section through a portion of the apparatus as seen along the line 2-2 of Fig. 1; and,v

Fig. 3 is a perspective view of a billet comprising a stack oi the plate-like briquettes:

Referring to Fig. 1 of the drawings, numeral I designates a reducing furnace, preferably of the type utilizing the method in which finelydivided oxides are reduced by preheated reducing gases below the temperature at which the particles agglomeratie and frit together, and in which the reducing gas is supplied to the bottom of a bed of oxide under such conditions as to impart to the bed a uid-like condition so that it flows along the hearth while being reduced. Methods and apparatus of this type are disclosed in copending-application Serial No. 338,560, filed June 3, 1940, by J. C. Hartley, or application Serial No. 360,418, flied October 9, 1940, by applicant and J. C. Hartley, now Patent No. 2,316,664, issued April 13, 1943, or application Serial N0. 481,968, led Apri] 6, 1943, by applicant and C. F. Ramseyer, or application Serial No. 484,960, filed April 29, 1943, by applicant.

The reduced ilnely-divided material discharged by the furnace I0 through hopper II is supplied to briquetting rolls I2 which are provided with' parallel alternate ridges and depressions so arranged that the depressions in one of the rolls cooperates with a ridge in the other roll, so that the elongated rectangular plate-like briquette B produced by the rolls I2 is corrugated transversely as shown in Fig. 3.v The dimensions oi the brio-nette B are determined by the size of the billet desired, and preferably is fromy one to three feet wide and two to six feet long, with a web thickness of from one-fourth to one inch. The rolls I2 have diameters and dimensions to accommodate the size of briquette desired and are provided with cooperating transverse cut-off ridges I3. Prior to briquetting, the material may be further concentrated magnetically as described in Patent No. 2,287,663, or in copending application Serial No. 485,195, filed April 30, 1943, by applicant, and the material is maintained in a reducing atmosphere, so as to preclude reoxidation as is described in greater detail in said Patent No. 2,287,663. Also, briquetting is effected immediately upon discharge of the material from the reducing furnace I0 so that the heat rof reduction is retained and contributes to the effective compacting of the particles into the platelike briquettes B.

The briquettes B are deposited by the briquetting rolls l2 upon a chute I4 down which they slide to be discharged upon the platform I5 of a stacking apparatus generally designated I5 and comprising a series of such platforms I5 carried upon a driven belt or chain I1 moving in a vertical direction over upper sprocket I8 and lower sprocket I9, thelatter being driven from a source of power, not shown. The rate of movement of the platforms I5 is such as to permit the collection of a predetermined number of briquettes B upon each platform I5 as it passes the chute I4, before the next succeeding platform I5 moves opposite chute I4 for collecting an equal number of the briquettes B. The stackin-g apparatus I6 may be of any form, the form shown serving merelyto illustrate one type of apparatus -which may be used for the purpose.

In the particular stacking machine I5 shown,

two chains I'I carry the platforms I5 which have diagonal braces engaging studs 20' on the chain I1 when moving downwardly in a vertical position so the platform I5 is held firmly and is supported so as to sustain the gradually increasing lload of the briquettes as they accumulate thereon. The chains I1 move over the frame 2I 4which holds the platforms steady in the course between the upper sprocket and the lower sprocket I9.

`As shown in Fig. 2, the iioor of each platform VIii of the; stacking apparatus I8, comprises spaced "parallel cantilever bars I5' providing longitudinal slots 22 so asto permit passage of the cantilever bars 23 of the corresponding plati form-f 23 ofconveyor 24, which accordingly removes the' stack of plate-like briquettes B from the platform I5 on which they are stacked in the sponding stacking platform I5.

Conveyor 24 is driven at a rate of speed such as to remove and convey each stack of briquettes B from the corresponding stacking platform I5 before the nextsucceeding platform approaches. The shaft 28 carrying the sprockets 25 of the conveyor 24 over which the chains 25 pass is tted with a smaller sprocket 29 driven by chain 30 connected to sprocket 3I on the shaft 29 of the stacking apparatus I6, or the conveyor 24 may be separately driven. if desired.

Conveyor 24 carries the stack of briquettes B into the muille or other heating furnace 32, wherein the temperature of the stack of briquettes B is raised to the welding point whereby the particles constituting the individual briquettes fuse together and the briquettes also fuse together to a certain extent to form a relatively unitary structure or billet B', but the temperature is not sufficiently high to cause melting, so that the billet B' retains its shape. The billet B' so formed is conveyed directly by the conveyor 24 or other means into a conventional rolling mill 33, extrusion press, or other apparatus for forming the billet B.' into finished or semi-iinished steel products. For example, the entire billetl B' may be rolled or extruded into one nthrough a multiple draw plate, or divided into'a.-

plurality of strands for forming the same into a -V plurality of like or unlike rods, wires, bars, or other shapes.

Preferably in order to preclude reoxidation of the reduced material constituting the plate-like briquette B, the entire apparatus described up to muiiie 32 is enclosed in a housing 34 containing a reducing atmosphere, either reducing gas emerging from the reducing furnace I0 into housing 34 with the reduced material or separately supplied. Also the heating in muiiie 32 is preferably conducted in a non-oxidizing atmosphere so that practically pure virgin metal is supplied to the rolling mill, extrusion press, or other finishing or semi-iinishing apparatus 33.

The corrugations 35 formed longitudinally of the briquette B provide for the accurate alignment of the briquettes B one upon -the other as they are discharged by chute I4 upon platform I5 since the corrugations of adjacent briquettes B interfit, as shown in Fig. 3. The alignment of the briquettes longitudinally is effected by the frame of the platform I5 but to facilitate such alignment the briquette may be provided with a transverse corrugation 36, either at the center as shown in Fig. 3, or at one end thereof, depending upon requirements.

The billet B' has dimensions determined by the dimensions of the briquette B and the number of them that are superimposed. Preferably it is made square in transverse section and has dimensions of from about one to three feet square in transverse section and from about two to six feet long, and may run as large as four 'feet square in transverse section by twelve feet long, and even larger, depending upon requirements, and the availability of heavy presses. Of course the briquettes are then proportionately larger and thicker.

It will be observed that the corrugations 35 and 36 serve to stiffen and hence provide a relatively rigid briquette, which is self-sustaining and will not -break or shatter when deposited upon chute I4 or platform l5. The corrugations also serve to facilitate stacking and to increase the surface area of the briquettes to facilitate heating in the muie 32 and consolidation of the billet B when the temperature thereof reaches the welding point in mufile 32. Mechanical consolidation of the particles and briquettes constituting billet B may be effected prior to rolling, extruding, or forging by passing the billet B through rolls or a forging hammer or press before feeding it into the finishing or semi-finishing apparatus 33, to which it is preferably fed in the direction of the length of the briquettes originally constituting it, i. e., in the direction of the long corrugations 35 in Fig. 3, in order to have a somewhat elongated grain structure.

As aforementioned, modifying agents, such as alloying metals, carbon and the like, may be admixed with the reduced material discharged from furnace I0 into chute Il prior to briquetting, as described in said. Patent No. 2,252,697, so that when the extrusion, rolling, forging, or other forming operation is effected, the physical and chemical characteristics of the finished material may be predetermined to provide the properties desired.

Although a preferred apparatus is illustrated and described in connection with the drawings, it is to be understood that the invention is not limited thereby but is susceptible of changes in form and detail within the scope of the appended claims.

I claim:

l. In apparatus for making iron and steel products, the combination of means for reducing flnely-divided iron oxides at a temperature below those at which the particles agglomerate and frit together, compacting rolls for compacting the finely-divided material discharged by said reducing means,`means for dividing said compacted material into plate-like briquettes, conveying means adjacent said rolls for receiving said briquettes in superimposed flatwise relation as they are discharged by said rolls, a heating furnace, means for transferring the said briquettes in said superimposed relation from said conveying means to said heating furnace, and deforming apparatus for deforming the heated superimposed briquettes into a unitary metal product.

2. In apparatus for making iron and steel pro-ducts, the combination of means for reducing finely-divided iron oxides at temperatures below those at which the particles agglomerate and frit together, compacting rolls having corrugated surfaces for compacting the finely-divided material discharged by said reducing means, means for dividing said compacted material into longitudinally corrugated plate-like briquettes, conveying means adjacent said rolls for receiving said briquettes in superimposed flatwise relation as they are discharged by said rolls, the said corrugations in adjacent superimposed briquettes intertting to cause them to self-align with respect to each other, a heating furnace, means for transferring the said briquettes in said superimposed relation from said conveying means to said heating furnace, and deforming apparatus for deforming the heated superimposed briquettes into a unitary metal product.

3. In apparatus for making metal products, the combination of means for reducing metallic oxide f material at temperatures below those at which the material frits or agglomerates, means for compacting the finely divided reduced material into strip form, means for dividing the strip of compacted material into separate self-sustaining plate-like briquettes, means for receiving and stacking a plurality of said briquettes in parallel and contacting relationship, and means for welding and deforming said stack of briquettes into a substantially uniform product.

4. In apparatus for making metal products, the combination of means for reducing metallic oxide material at temperatures'below those at which the material frits and agglomerates, and means for simultaneously compacting the finely divided reduced material into strip form and corrugating the strip of material, dividing the compacted and corrugated strip of material as formed into separate self-sustaining plate-like corrugated briquettes, means for receiving and stacking a plurality of said briquettes in parallel, contacting relationship, and means for welding and deforming said stack of briquettes to form a substantially uniform metal product.

HERMAN A. BRASSERT. 

